tripac™ evolution · inside the tractor provided you adhere to the following conditions: †...

Installation Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2013 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

TriPac™ EVOLUTION Auxiliary Heating and Cooling

Temperature Management SystemTK 55676-19-IM (Rev. 5, 10/15)

Installation Manual

TriPac™ EVOLUTION

Auxiliar Cooling Tempera ment SystemTK 55676-19-IM (Rev.

t© 2013 Ther A. U.S.A.

CopyrighPrinted in

y Heating andture Manage

5, 10/15)

mo King Corp., Minneapolis, MN, U.S.

2

n Manual

ew heater diagnostic tool.

allation procedures required for 120 Amp

tions and illustrations to show new air intake tube with D2. Pages 3, 9, 58, 60, 66, 68, 70 and 88: ly during the APU installation to help reduce

rectly route and secure the refrigerant hoses from

ration hoses to APU support bracket, pages 60- interface board, page 89: corrected terminal pin

TriPac EVOLUTION InstallatioRelease HistoryReleased (06/13)

Rev. 1 (07/13) Pages 94-99: Updated heater start-up procedures for n

Rev. 2 (10/13) Pages 74-75: Added Ambient Temperature Sensor instalternator option.

Rev. 3 (04/14) Pages 22, 23, 40-43: Updated heater installation instrucassembly, combined D4 heater installation instructions added information about installing options simultaneousoverall installation time.

Rev. 4 (02/15) Pages 54-57: Updated art and text to clarify how to corthe APU’s compressor to the hose support bracket.

Rev. 5 (10/15) Pages 54-55: Updated instructions for attaching refrige61:updated instructions for attaching new ground wire toorientation on illustration.

3

y Heating and Cooling System onto a typical vide the installer with details to correctly and iesel Particulate Filter (DPF), Power Inverters, sly with the APU when possible to help reduce

riPac components by using the TriPac ment that may be necessary to complete the

u should not attempt this installation unless

chanic.

34 kilos).

ertified and trained in the repair and maintenance geration systems.

ding of electricity and electrical wiring.

ls and equipment to complete the installation.

arranties express or implied, with respect to ot be regarded as all-inclusive or covering

hould be consulted.

repaired or altered as, in the manufacturer’s

damage or any other direct, indirect, information, recommendations or

Introduction

This manual was written to assist with the installation of the Thermo King TriPac EVOLUTION Auxiliarsemi tractor. While not intended to be specific to a particular vehicle, the information in this manual will prosafely install each of the standard TriPac APU components. Thermo King offers numerous options such as DHourmeters, etc. which have separate installation instructions. These options should be installed simultaneouoverall installation time.

Before beginning the installation, the installer should confirm with the customer the location for each of the TInstallation Questionnaire. The customer should also be made aware of any modifications to existing equipinstallation.

Modifications may include:

• OEM components on the chassis may need to be relocated to accommodate the installation of the TriPac APU.

• Fuel tank may need to be changed to a smaller size.

• TriPac components will be mounted onto the outside of the sleeper.

• Existing storage space under the bunk will be utilized by TriPac components.

• Heating and A/C duct work will be routed and vents will be installed in existing closets or storage compartments.

Due to its complexity, yoyou:

• are an experienced me

• can safely lift 75 lbs. (

• are EPA Section 609 cof diesel powered refri

• have a basic understan

• have the necessary too

This manual is published for informational purposes only. Thermo King makes no representations wthe information recommendations and descriptions contained herein. Information provided should nall contingencies. If further information is required, Thermo King Corporation Service Department s

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, propertyspecial, or consequential damages whatsoever, arising out of the use of this manual or any descriptions contained herein.

4

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Heater Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Tips for a Successful Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

APU Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Condenser Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Evaporator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Control Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Required Tools and Additional Supplies . . . . . . . . . . . . . . . . . . . . . . . . 20

Typical Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

TriPac Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

APU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Exhaust Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

A/C Condenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

A/C Receiver Drier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Ambient Temperature Sensor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . .32

A/C Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

D2/D4 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

D2/D4 Heater Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

A/C Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fabricating Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

A/C Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

A/C System Evacuation and Leak Check Procedures . . . . . . . . . . . . . . .58

Control Box and Main Harness Installation. . . . . . . . . . . . . . . . . . . . . . 60

HMI Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

D2/D4 Heater Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

A/C Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Standby Truck Integration Harness with Switch (Option) . . . . . . . . . . .70

Standby Truck Integration Harness without Switch (Option) . . . . . . . . 72

Fuel Pickup Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Heater Fuel Pump and Fuel Line Installation . . . . . . . . . . . . . . . . . . . . 78

APU Fuel Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Tractor Coolant Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Arctic Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Heater Fuel Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Fuse Holder and APU Battery Connections . . . . . . . . . . . . . . . . . . . . . .90

Priming the Heater Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Heater Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

A/C System Charging and APU Engine Start-up Procedures . . . . . . . .100

Unit Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

TriPac EVOLUTION Unit Run-In Procedures . . . . . . . . . . . . . . . . . . .112

System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

5

unit before completing the , coolant hoses, adding the

before completing the ier, connecting the m with the correct type and

it the potential harm to the sphere.

of refrigerant into the

Safety Precautions

CautionSEVERE DIESEL ENGINE DAMAGE will result from operating the TriPac APUinstallation which includes: adding engine oil, installing fuel pump, fuel linescorrect type antifreeze and bleeding air from coolant lines.

SEVERE COMPRESSOR DAMAGE will result from operating the A/C system installation which includes: installing the condenser, evaporator, receiver drrefrigeration lines, leak testing, evacuation, clean-up, and charging the systeamount of refrigerant.

Recover RefrigerantAt Thermo King, we recognize the need to preserve the environment and limozone layer that can result from allowing refrigerant to escape into the atmo

We strictly adhere to a policy that promotes the recovery and limits the loss atmosphere.

6

tant:

will

ht

,

ear goggles or safety glasses. Refrigerant il, and battery acid can permanently damage under Refrigeration Oil).

r hands away from fans and belts when the

re all mounting bolts are tight and are of ir particular application

ill holes into the unit. Holes drilled into the ctural components. Holes drilled into cause fire or explosion.

ing ladders to install or service refrigeration ve the ladder manufacturer’s safety labels and tform is the recommended method for

coil fins are very sharp and can cause painful

Safety Precautions

The symbol appears next to a point that is particularly impor

DANGER: Addresses a circumstance that, if encountered, lead to death or serious injury

WARNING: Addresses a circumstance that, if encountered, miglead to death or serious injury.

CAUTION: Addresses a circumstance that, if encounteredmay cause damage to equipment or minor injury.

DANGER: When the APU is installed behind tractor fairings, skirting, etc., the exhaust outlet must be routed out to an open area to prevent exhaust fumes from entering the passenger compartment which could result in in carbon monoxide poisoning or death by asphyxiation.

DANGER: Never apply heat to a sealed refrigeration system or container because it could explode, causing death or serious injury

DANGER: Fluorocarbon refrigerants, in the presence of an open flame or electrical short, produce toxic gases that are severe respiratory irritants capable of causing death.

DANGER: Be careful when working with a refrigerant or refrigeration system in any enclosed or confined area with a limited air supply (i.e., a trailer, container or the hold of a ship). Refrigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation.

WARNING: Always wliquid, refrigeration othe eyes (see First Aid

WARNING: Keep youunit is running.

WARNING: Make sucorrect length for the

WARNING: Never drunit may weaken struelectrical wiring can

WARNING: When ussystems, always obserwarnings. A work plainstallations.

WARNING: Exposedlacerations.

7

frost bite, the objectives of First Aid are to rther injury, to warm the affected area tion.

, immediately flush eyes with large amounts al attention.

mounts of lukewarm water. Do not apply othing and shoes. Wrap burns with dry, ct from infection/injury. Get medical clothing before reuse.

o fresh air and use CPR or mouth-to-mouth ith victim until arrival of emergency

t, immediately flush with plenty of water A PHYSICIAN. Wash skin with soap and

luorocarbon refrigerants are classified ertain precautions must be observed r servicing a unit in which they are

to the atmosphere in the liquid state, nts evaporate rapidly, freezing anything

geration oil contact with the eyes. Avoid contact of refrigeration oil with skin or ghly after handling refrigeration oil to

Safety Precautions

Battery Cable Installation and Routing Refrigerant

First Aid

FROST BITE: In the event ofprotect the frozen area from furapidly and to maintain respira

EYES: For contact with liquidof water and get prompt medic

SKIN: Flush area with large aheat. Remove contaminated clsterile, bulky dressing to proteattention. Wash contaminated

INHALATION: Move victim tventilation, if necessary. Stay wmedical personnel.

Refrigeration Oil

First Aid

NOTE: In case of eye contacfor at least 15 minutes. CALLwater.

WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.

WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire!

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty!

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

WARNING: Although fas safe refrigerants, cwhen handling them oused. When released fluorocarbon refrigerathey contact.

WARNING: Avoid refriprolonged or repeatedclothing. Wash thorouprevent irritation.

8

nsEFORE installing the heater, thoroughly read and

PHYXIATION HAZARD! Failure to follow these ould cause oxygen depletion resulting in serious or

heater exhaust so that exhaust fumes can not enter ssenger compartments.

air tight seal will be maintained between the heater ting surface and at any exhaust connection points.

t heating air supply is taken from an area where gases will not be present.

heater is installed in a enclosed compartment separate vaporator, a inlet for return air must be installed to e heater with a fresh air supply.

exhaust components through an enclosed ent, ensure that it is vented to the outside.

sed compartment must be free of any holes, cracks or areas to prevent fumes from entering into the compartment.

must be installed flush with the floor pan (i.e. sheet rglass, etc.) to ensure proper sealing of the mounting asket.

must not be operated in closed areas such as garages, warehouses, etc.

ale exhaust fumes.

isconnect the heater harness at the battery before e truck chassis to prevent damage to the electronic er.

Heater Safety PrecautioIMPORTANT: Correct installation of this heater is necessary to ensure safe and proper operation. Bunderstand this manual and the heater manufacturer’s manuals included with the heater.

DANGER: EXPLOSION HAZARD or FIRE HAZZARD! Failure to follow these instruction could cause a explosion or fire resulting in serious or fatal injury!• Heater must be turned off while re-fueling.

• Install heater so it will maintain a minimum distance of 2” from any flammable or heat sensitive material.

• Install the exhaust system so it will maintain a minimum distance of 2” from any flammable or heat sensitive material.

• Stored items in may shift while vehicle is in operation and should be secured adequately to prevent contact with the heater.

• Use a protective air intake grille on the air inlet side of the heater to prevent objects from being sucked in.

• The heater must only be operated when the maintenance flap is closed and the outlet hood is mounted in position.

• Do not install heater in enclosed areas where combustible fumes may be present.

• Do not store or transport combustibles (road flares, starting fluids, fuel containers, oil cans, spray cans, gas cartridges, fire extinguishers, cleaning rags, clothing, paper, etc.) in the same compartment as the heater.

• Ensure that the fuel system is intact and there are no leaks.

• Do not route electrical wires, harness or battery cables together with fuel lines.

DANGER: ASinstructions cfatal injury!

• Route the into the pa

• Ensure anand moun

• Ensure thapoisonous

• When the from the eprovide th

• If runningcompartm

• The enclorusted outpassenger

• The heatermetal, fibeplate and g

• The heaterbuildings,

• Do not inh

CAUTION: Dwelding on thHMI controll

9

on

rt of the tractor’s frame or drill holes in the top s structural damage could occur. Consult your further information.

e mounted only to the existing frame rails. G IS ACCEPTABLE!

on for installing the APU on the existing

onents on the chassis frame rail that interfere e APU.

APU before installing.

ATV lift or modified floor jack to raise APU nded.

blocks and mounting claws must be used to assis frame rail.

ts are used they must be Grade 5 and of the cut off excessive length bolts.

er APU mounting bolts are flush with the tightening.

securing the APU to the tractor’s frame must nd torqued using the four-step tightening “APU Installation” on page 24.

r removable panels must be in place and perating the system.

APU is installed behind fairings, skirting, t must be routed to an open area to prevent ntering the passenger compartment which monoxide poisoning or death by

Tips for a Successful Installati

BEFORE BEGINNING THE INSTALLATION• Read this manual to understand where components are to be located

and how they are to be installed.

• Thermo King offers numerous options such as Diesel Particulate Filter (DPF), Power Inverters, Hourmeters, etc. which have separate installation instructions. These options should be installed simultaneously with the APU when possible to help reduce overall installation time.

• Review the TriPac component drawings for important minimum/maximum dimensions and clearances that must be taken into consideration when installing these components.

• Verify tools and special equipment required for the installation are available and in good working condition.

• Open all TriPac kits and inspect contents before beginning installation.

• Review component location diagram and discuss with the customer where the TriPac components will be installed.

• It is recommended that one person performs the installation of all the components outside the sleeper while a second person installs all the components inside the sleeper. This will help minimize damage to the sleeper’s interior from grease, dirt, etc.

APU INSTALLATION

• DO NOT weld on any paor bottom flanges. Seriouchassis manufacturer for

• The APU is designed to bNO OTHER MOUNTIN

• Determine the best locatichassis frame rail.

• Safely relocate any compwith the installation of th

• Check clearance around

• The use of a motorcycle/into position is recomme

• Only the supplied spacerinstall the APU to the ch

• If different mounting bolcorrect length. DO NOT

• Verify the upper and lowchassis frame rail before

• The mounting hardware be correctly positioned asequence described in the

• All APU covers, guards oinstalled securely while o

DANGER: When theetc., the exhaust outleexhaust fumes from ecould result in carbonasphyxiation.

10

lation

OR INSTALLATION system fittings capped and sealed until the refrigeration hoses.

t location for the A/C evaporator inside the sleeper, e bunk.

interference with any OEM electrical wiring, internal re drilling any mounting holes.

ould be mounted directly onto the floor mat inside ng the supplied template to locate the drain and

drain valves (kazoos) onto evaporator drain tubes e clamps.

ould be located and installed to provide maximum air sleeper such as: LOW (floor level), MEDIUM (above or HIGH (above upper bunk level).

s must be sealed with silicone caulk to prevent st fumes from entering the sleeper.

s holes made in fiberglass and wood composite floors rrectly with fiberglass cloth and resin.

Tips for a Successful Instal

A/C CONDENSER INSTALLATION• Always keep A/C system fittings capped and sealed until the

installation of the refrigeration hoses.

• Determine the best location to mount the condenser onto the exterior of the sleeper.

• Verify all measurements before drilling any mounting holes.

• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before drilling mounting holes.

• Confirm the condenser location does not interfere with the service or operation of existing tractor components.

• Provide protection to the tractor’s finish to prevent damage during the installation process.

• Use the stainless steel mounting hardware (supplied in the kit) to mount the condenser coil.

• Use the large fender washers (supplied in kit) inside the sleeper to provide additional support.

• All mounting holes must be sealed with silicone caulking to prevent moisture or fumes from entering the sleeper.

A/C EVAPORAT• Always keep A/C

installation of the

• Determine the bestypically under th

• Verify there is no supports, etc. befo

• The evaporator shthe sleeper by usimounting holes.

• Always install thesecurely with hos

• The A/C vents shcirculation in the lower bunk level)

• All mounting holemoisture or exhau

• All edges of accesmust be sealed co

11

tion

tlet ducts must be installed correctly for the heater

be installed at a 15 to 35 degree angle from orrectly.

t be installed correctly in the fuel tank or the .

kup tube to the fuel pump to the heater should be rise.

harp knife to cut plastic fuel lines. Do not use a l pinch the plastic fuel line closed.

l wires, harness or battery cables together with

e heater, the fuel lines must be bled of air using arness (204-1144) or damage to the fuel pump

Reader (204-1143) must be used to setup and he run-in mode.

Tips for a Successful Installa

D2/D4 HEATER INSTALLATION• Determine the best location of the heater inside the sleeper, typically

under the bunk. Allow clearance for dismantling for service.

• Install heater so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable material.

• Heater must be mounted on a flat horizontal surface.

• Heater must be installed flush with the floor pan (i.e. sheet metal, fiberglass, etc.) to ensure proper sealing of the mounting plate and gasket.

• All edges of access holes made in fiberglass and wood composite floors must be sealed correctly with fiberglass cloth and resin.

• Outside air intake and exhaust hoses must be installed correctly for the heater to operate safely.

• Exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install exhaust hose so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable material.

• Inside air inlet and outo operate safely.

• Pulse fuel pump musthorizontal to operate c

• Fuel pickup tube musheater will not operate

• Fuel line from the picrouted at a continuous

• Use a hose cutter or swire cutter as this wil

• Do not route electricafuel lines.

• BEFORE operating ththe Heater Priming Hwill result.

• The Diagnostic Code operate the heater in t

12

on

OSE CONNECTIONS AND

PU’s equipped with Tractor Coolant

routed from the APU to the tractor’s engine or kinks.

installed and routed in such a way as to allow ent. THEY SHOULD NEVER BE

protected with supplied plastic sleeving and chassis with clamps and band wraps.

s from rubbing or chafing against sharp metal nts or hot objects.

nstalled should be of proper material type, per to copper).

d be assembled using pipe thread sealer to

supplied) should be installed to allow the be closed off and isolated from the tractor’s

s must be adequately supported to prevent ation.

LINGe without first adding coolant and bleeding all

Tips for a Successful Installati

A/C HOSE CONNECTIONS AND ROUTING• Always keep A/C system fittings capped and sealed until the

installation of the refrigeration hoses.• Only cut refrigerant hoses with the correct hose cutting tool (204-677).

NEVER USE A SAW!• Always use the correct hose fitting tool (204-1045) when assembling

refrigeration hoses.• Always lubricate hose fittings with PAG 100 refrigerant oil (203-544)

when assembling to refrigeration hoses.• Always install and lubricate O-rings with PAG 100 refrigerant oil

(203-544) when connecting refrigeration hose fittings to component connection fittings.

• Refrigeration hoses should be installed onto components in such a way as to allow for vibration and movement of the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!

• All refrigeration connections should be tightened securely using two wrenches.

• Always keep refrigeration hoses from rubbing or chafing against sharp metal objects, rotating components or hot components.

• Protective covers or sleeving (installer supplied) for the refrigeration hoses may be required depending on the installation.

• Always install the condenser’s receiver drier in the direction indicated by the arrow.

• Thermo King Evacuation Station (204-725) and Evacuation Station Operation and Field Application Instructions (TK-40612) are recommended.

• The oil in the evacuation station vacuum pump should be changed after each use.

• The A/C system must be leak free. Check for leaks by using an electronic leak detector.

• The A/C system will be charged with 1.2 to 2.0 bs. (depending on hose lengths) of R134a.

ENGINE COOLANT HROUTINGThe following steps are for AIntegration only.

• Coolant hoses should be without any sharp bends

• Coolant hoses should be for vibration and movemSTRETCHED TIGHT!

• Coolant hoses should be adequately secured to the

• Always keep coolant hoseobjects, rotating compone

• All coolant pipe fittings i(i.e: brass to brass, or cop

• All coolant fittings shoulprevent leaks.

• Ball type shutoff valves (TriPac cooling system toengine cooling system.

• Shutoff valves and fittingcracks or leaks from vibr

CLOSED LOOP COODo not start the APU’s enginair from the system.

13

llation
Tips for a Successful Insta
ELECTRICAL WIRING AND HMI CONTROLLER INSTALLATION• Electrical wiring should be installed and routed in such a way as to

allow for vibration and movement of the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!

• Always keep electrical wiring from rubbing or chafing against sharp metal objects, rotating components or hot objects.

• All electrical wiring should be neatly routed and secured with band wraps or clamps.

• Do not route electrical wires, harness or battery cables together with fuel lines.

• Excess length of battery cables should be cut off to reduce voltage drop.

• Superlube (203-524) or equivalent should be applied to all electrical connections.

• All main power and ground accessory connections must be installed directly on top of the tractor’s battery terminal posts and tightened securely. DO NOT INSTALL UNDER OEM BATTERY CABLES!

• The HMI should be visible and mounted away from windows, air vents, out of direct sunlight and not touching anything to accurately measure air temperature.

14

APU Dimensions

15

APU Dimensions

16

s
Condenser Dimension

17

s.

Evaporator Dimensions

NOTE: Dimensions are shown in inche

18

s
Control Box Dimension

19

BLANK PAGE

20

Supplies

Required)gs (for coolant lines)

ow, MPT x FPT

ow, MPT x FPT

PT x FPT

1/2” NPT to 3/4” Hose

le, 1/2” NPT

ad Tape (for coolant fittings)

2 gallons (must be the correct type to match original)

3-391)

Oil (203-544)

.

ouver aprox. 6” x 10” (when needed)

.51” to 0.16” w/adhesive (for battery cable terminals)

s #24 and #32 (to secure cables and hoses)

orted sizes and lengths)

ner (aprox. 2 cans)

nkets (to protect interior)

r Kiterglass and wood composite floors)

Required Tools and Additional

Tools1. Typical Mechanics Tools2. Floor Jack or Motorcycle/ATV Lift3. Drill Motor4. Drill Bit Set5. 7/8” dia. or 1” Step Reamer (for evaporator drain and controller holes)6. Hole Saws

• 1-1/4” dia. (for fuel tank pickup tube)• 2-1/2” dia. (for heater outlet louver)• 3” dia. (access hole for evaporator hoses and electrical wiring)• 4-1/4” dia. (mounting A/C louvers, routing A/C ducts through

bulkheads and heater mounting hole)

7. Reciprocating Saw (return air opening)8. 1/2” Drive Torque Wrench9. Level10. Tape Measure11. Utility Knife12. Caulk Gun13. Tubing Cutter (for cutting fuel pickup tubes)14. Strobe Light/Tachometer (204-436)15. Digital Meter (204-615)16. Leak Detector (204-756)17. Hose Fitting Tool (204-1045)18. Hose Cutting Tool (204-677)19. Heater Priming Harness (204-1144)20. Heater Diagnostic Tool (204-1143)21. Shop Vacuum

Supplies (As1. 1/2” Brass Fittin

• 45 degree elb

• 90 degree elb

• Tee, FPT x F

• Hose Fitting,

• Closed Nipp

2. Teflon Pipe Thre

3. Antifreeze, up to

4. RTV Silicone

5. Sealing Putty (20

6. PAG Refrigerant

7. Refrigerant 134A

8. Return air wall l

9. Shrink Tubing 0

10. Mounting Clamp

11. Band wraps (ass

12. Upholstery Clea

13. Cardboard or bla

14. Fiberglass Repai(only used for fib

21

onsr Design

Typical Component Locati

TRIPAC COMPONENTS

1. A/C Evaporator 4. Control Box

2. Return Air Grille(Installer Supplied)

5. TriPac APU

3. Heater 6. A/C Condenser

NOTE: Component Locations Will Vary With Sleepe

22

tion

er’s Fuel Pump

Supply and Return Lines

ant Supply and Return Hoses

tor’s Heater Core

TriPac Component DiagramAPU’s Equipped with Tractor Coolant Integra

1. APU with Tractor Coolant Integration 5. HMI Controller 9. Heat

2. A/C Condenser 6. Heater 10. Fuel

3. A/C Receiver Drier 7. Heater’s Exhaust Tube 11. Cool

4. A/C Evaporator 8. Heater’s Intake Tube 12. Trac

Sleeper

23

Fuel Pump

ply and Return Lines

leeper

TriPac Component DiagramAPU’s Equipped with Closed Loop Cooling

1. APU with Closed Loop Cooling 5. HMI Controller 9. Heater’s

2. A/C Condenser 6. Heater 10. Fuel Sup

3. A/C Receiver Drier 7. Heater’s Exhaust Tube

4. A/C Evaporator 8. Heater’s Intake Tube

S

Closed Loop Cooling Expansion Tank

24

NG CLAWS

h, torque mounting bolts in four step increments s, then bottom bolts.

then bottom mounting bolts to 25 ft-lb. (33.9

P and verify all mounting claws and bolts me (Detail A). If they are not, loosen bolts, and retighten again to 25 ft-lb. (33.9 N•m).

tep is successfully completed, torque top then ts to 50 ft-lb. (67.8 N•m).

e top and then bottom bolts to 100 ft-lb. ).

heck all bolts to confirm they are at 100 ft-lb. )

NOT OVER-TORQUE MOUNTING BOLTS!

lift and visually inspect installation for the

nd bolts are correctly installed. They should be the frame (Detail A).laws and bolts are improperly installed on the esemble Details B & C) - adjust as necessary.ed or cracked components during installation -

mmediately.

APU Installation

STANDARD INSTALLATION METHOD - MOUNTI

Installation

1. Remove top cover of TriPac APU to access and remove mounting hardware securing APU to shipping crate.

2. It is recommended that a modified floor jack or motorcycle/ATV lift be used to install the APU. Protection such as cardboard, shop rags, etc. should be used under the APU to prevent damage during installation.

3. Raise the APU into position. From outside the APU, insert the 3/4 in. mounting bolts and washers through mounting claws and spacer blocks (slots go down) and into APU’s frame mounting holes.

4. From inside the APU, loosely install washers, nut retainers and locking nuts in that order. DO NOT OIL THE BOLT THREADS!

5. With APU still supported by a lift:

• Push APU and spacer blocks up tight to tractor frame.

• Adjust height of the APU so top and bottom mounting claws and bolts are positioned flat on frame. Review (Detail A). Lightly tighten mounting hardware only enough to remove excess play.

6. Using a torque wrencstarting with top bolt

STEP 1- Torque top N•m).

IMPORTANT: STOremained flat on fraadjust as necessary

STEP 2- After first sbottom bol

STEP 3- Next, torqu(135.6 N•m

STEP 4 - Finally, rec(135.6 N•m

IMPORTANT: DO

7. Remove the support following:

• Mounting claws asquare and flat on

• If any mounting cframe (i/e. they r

• Damaged, deformmust be replace i

Special Tools Required

Modified Floor Jack or Motorcycle/ATV Lift

1/2” Drive Torque Wrench

WARNING: The following steps are critical and must be followed to ensure the safe installation of the APU to the tractor’s frame.

25

APU Installation

26

Extensionsses short tail pipe supplied with APU)

ng bracket onto the side of the APU.

on pipe and clamp onto the end of the muffler.

xhaust tailpipe (supplied with APU) and clamp.

outlet down or towards the rear of the tractor.

s securely.

utlet must be routed to an open area to prevent poisoning or death by asphyxiation. Optional

Exhaust Pipe Installation

Short Exhaust TailpipeA short exhaust tailpipe is provided with each APU.

• Install the short exhaust tailpipe (outlet facing down) onto the end of the muffler and secure with clamp.

Optional Exhaust Two Piece Extension (u

• Install the mounti

• Install the extensi

• Install the short e

• Face the tailpipe

• Tighten all clamp

DANGER: When the APU is installed under a sleeper, behind fairings, skirting, etc., the exhaust oexhaust fumes from entering the passenger compartment which could result in carbon monoxide exhaust pipe extensions are available for this purpose. Contact your nearest Thermo King Dealer.

27

Exhaust Pipe Installation

Short Exhaust Tailpipe Two Piece Exhaust Extensionwith Tailpipe

28

ion

rk the exterior center line of the sleeper.

the condenser onto the sleeper with the #8 fitting ark the mounting holes; typically one in each corner.

ounting holes.

RTV silicone along the entire condenser mounting nd each of the four mounting holes.

nser with 3/8” stainless mounting bolts and large rom the inside, and 3/8” washers and locking nuts on ten hardware securely.


re

nd RTV Silicone Sealant

A/C Condenser Installat

A/C Condenser LocationLocate an area on the exterior of the sleeper to install the condenser that does not interfere with the operation of existing truck components. If possible mount the condenser below the bunk level. This allows easier access to four 3/8” bolts with large fender washers inside without disturbing interior panels.

IMPORTANT: Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling into the truck’s interior support members as this could void the tractor’s OEM warranty.

The condenser housing and coil assembly can be also installed with the hose fittings facing towards the roadside (DETAIL A) if needed. When doing so, the actual condenser coil must be removed from the housing and rotated so the #8 fitting is on top by:

• rotating the complete condenser housing and coil assembly so the hose fittings are facing towards the roadside.

• removing the condenser coil from the housing, and rotating it so the #8 fitting is positioned at the top, then install it back into the condenser housing and tighten the hardware securely.

Installation

1. Measure and ma

2. Center and levellocated on top. MDrill four 3/8” m

3. Apply a bead of flanges and arou

4. Install the condefender washers fthe outside. Tigh

Tape Measu

Level

Drill Motor

3/8” Drill Bit

Caulk Gun a

29

A/C Condenser Installation

30

ation

l the receiver drier bracket and mark each of the two Drill two 3/8” holes.

hose clamps to the bracket with 3/8” stainless washers and locking nuts (installer supplied) and

facing out, install the receiver drier onto the bracket ose clamps securely.


A/C Receiver Drier Install

A/C Receiver Drier LocationLocate an area on the exterior of the tractor to install the receiver drier.

It is recommended to mount the receiver drier directly onto the sleeper to reduce hose flexing.

Typical Mounting Locations:

• Side-by-side Mount (DETAIL A).

• Mid-height Mount (DETAIL B).

• High Mount (DETAIL C).

Installation

1. Position and levemounting holes.

2. Attach two largemounting bolts, tighten securely.

3. With the switch and tighten the h

Drill Motor

3/8” Drill Bit

Level

31

tion
A/C Receiver Drier Installa

32

(Option)

073023

harness to the control box:

connector (J2) from controller.

TS) securely into connector (J2) pinout #4.

TS_RTN) securely into connector (J2) pinout #5.

pin connector (J2) securely into controller.

res with cable ties.

or and select Alternator Capacity - 120 Amps.

edures at back of manual.

Ambient Temperature Sensor

Included in 120 Amp Alternator Option

Installation1. Locate ambient temperature sensor harness supplied with unit.

2. Sensor should be mounted at highest point on either the receiver drier bracket or the condenser fan housing.

• DETAIL A - sensor can be mounted on either the receiver drier bracket or on the condenser fan housing as both are at equal height.

• DETAIL B - sensor should be mounted to the condenser fan housing as it is higher than the receiver drier.

• Attach sensor with the provided clamp and mounting hardware as shown.

3. Route sensor harness up inside the sleeper through existing access hole.

NOTE: Sensor harness should be secured with cable ties to the other harnesses already installed and routed into sleeper.

4. Route the sensor

• Unplug 6-pin

• Insert wire (A

• Insert wire (A

• Reconnect 6-

• Secure all wi

5. Go to TK Monit

See Unit Setup Proc

33

Option)

ensor Harness

nnector

Ambient Temperature Sensor (

Ambient Sensor

Sensor should be mounted at highest point on either the receiver drier bracket or the

condenser fan housing.

Ambient S

6-Pin (J2) Co

34

on

T BULKHEAD

ate flush with the bulkhead, mark the location of the ain holes and the 3” access hole. Remove the

t hole for the drain holes followed by a 7/8” step

hole.

iece of split loom (or similar) around the inside edge le to provide protection for the hoses and wiring.

porator mounting brackets attached to sides of the

in place and determine where the return air opening d on the bulkhead.

r opening (minimum opening size 14'' x 7''). Remove cut the opening. Install the evaporator to the floor

grille (installer supplied).

he sleeper:

water valves (kazoos) onto the evaporator drain re with supplied hose clamps.

e drain tube access holes with sealing putty or t.

sealant around the four evaporator mounting screws.

d holes, cracks, or visible air gaps that might be

A/C Evaporator Installati

PREFERRED LOCATION - FLUSH WITH FRONA/C Evaporator LocationA template is supplied to represent the amount of area needed to accommodate the evaporator. It also provides locations for the two 7/8” drain holes and the 3” access hole.

IMPORTANT ACCESS HOLE INFORMATION:

• The location of the 3” access hole will be determined by your particular sleeper construction, including OEM internal floor supports, electrical wiring, etc. It should be located directly behind the evaporator’s A/C fittings to allow the refrigerant hoses with 90 degree fittings to be attached and routed down through the floor easily.

• Floors made from fiberglass covered wood construction require the edges of the 3” access hole be completely sealed with fiberglass and epoxy resin.

• Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling into the truck’s support members.

Installation1. Position the templ

7/8” evaporator drtemplate.

• Drill 1/4” piloreamer.

• Drill 3” access

2. Cut and install a pof the 3” access ho

3. Reposition the evaevaporator.

4. Set the evaporatorneeds to be locate

5. Mark the return aithe evaporator andwith TEK screws.

6. Install a return air

7. From underneath t

• Attach the twotubes and secu

• Seal around thsilicone sealan

• Apply silicone

• Seal any unusefound.


Drill Motor

1/4” Drill Bit

7/8” Step Reamer

3” dia. Hole Saw

Reciprocating Saw

Caulk Gun and RTV Silicone Sealant

Sealing Putty (203-391)

Fiberglass Cloth and Resin Kit (if required)

35

nKHEAD

A/C Evaporator InstallatioPREFERRED LOCATION - FLUSH WITH BUL

14'' x 7'' minimum bulkhead opening

36

on

ER BUNK

ate under the bunk and mark the location of the in holes and the 3” access hole. Remove the

hole for the drain holes followed by a 7/8” step

hole.

iece of split loom (or similar) around the inside edge le to provide protection for the hoses and wiring.

porator mounting brackets attached to the sides of

tor to the floor with TEK screws.

r a return air opening (minimum opening sizehe opening. Install a return air grille (installer

he sleeper:

water valves (kazoos) onto the evaporator drain re with supplied hose clamps.

e drain tube access holes with sealing putty or t.

sealant around the four evaporator mounting screws.

d holes, cracks, or visible air gaps that might be

A/C Evaporator Installati

ALTERNATIVE LOCATION - CENTERED UNDA/C Evaporator LocationA template is supplied to represent the amount of area needed to accommodate the evaporator. It also provides locations for the two 7/8” drain holes and the 3” access hole.

IMPORTANT ACCESS HOLE INFORMATION:

• The location of the 3” access hole will be determined by your particular sleeper construction, including OEM internal floor supports, electrical wiring, etc. It should be located directly behind the evaporator’s A/C fittings to allow the refrigerant hoses with 90 degree fittings to be attached and routed down through the floor easily.

• Floors made from fiberglass covered wood construction require the edges of the 3” access hole be completely sealed with fiberglass and epoxy resin.

• Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling into the truck’s support members.

Installation1. Position the templ

7/8”evaporator dratemplate.

• Drill 1/4” pilotreamer.

• Drill 3” access

2. Cut and install a pof the 3” access ho

3. Reposition the evathe evaporator.

4. Install the evapora

5. Mark a location fo14'' x 7'') and cut tsupplied).


• Attach the twotubes and secu

• Seal around thsilicone sealan

• Apply silicone

• Seal any unusefound.


Drill Motor

1/4” Drill Bit

7/8” Step Reamer

3” dia. Hole Saw

Reciprocating Saw

Caulk Gun and RTV Silicone Sealant

Sealing Putty (203-391)

Fiberglass Cloth and Resin Kit (if required)

37

UNK

A/C Evaporator InstallationALTERNATIVE LOCATION - CENTERED UNDER B

14'' x 7'' minimum bulkhead opening

38

n

In Floor

er’s metal mounting plate onto the floor mat.

e to cut the floor mat around the outside edges of the oor mat to access the bare floor.

ng plate in position, center punch the four outer holes. nting plate and mark an “X” connecting the four uter holes.

center of the “X” and drill a 4-1/4” hole with a hole


h

ole Saw

loth and Resin Kit (if required)

D2/D4 Heater Installatio

Heater LocationIMPORTANT: Correct installation of this heater is necessary to ensure safe and proper operation. BEFORE installing the heater, thoroughly read and understand “Heater Safety Precautions” on page 8 of this manual along with the heater manufacturer’s manuals included with the heater.

The location for mounting the heater will vary depending on the type of tractor. Typically the heater is mounted inside the sleeper, under the bunk in a storage compartment. However, the heater may be mounted anywhere inside the tractor provided you adhere to the following conditions:

• Install heater so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable material.

• Combustion air intake, exhaust and fuel inlet must be located outside the tractor.


• Heater must be mounted on flat horizontal surface providing an air tight seal between heater and tractor.

• All floor matting, carpet, insulation, etc. must be removed to allow the heater to be mounted directly to the bare floor.

• Heater harness may be repositioned to either side of the heater.

• Floors made of fiberglass covered wood construction require the edges of the access hole be sealed with fiberglass and epoxy resin.

Drilling Hole

1. Position the heat

2. Use a utility knifplate. Remove fl

3. With the mountiRemove the moucenter punched o

4. Center punch thesaw.

Drill Motor

Utility Knife

Center Punc

4-1/4” dia. H

Fiberglass C

39

D2/D4 Heater Installation

40

n

ationer over the access hole with intake and exhaust hose ing the tractor. Attach the heater to the floor with TEK en securely.

screws sufficiently to ensure a positive seal between mounting surface. Do not over tighten!


Heater SubassemblyTurn the heater upside down and attach the following components:

1. Snap the air outlet hood onto the end of the heater.

2. Place the mounting plate onto the heater studs. Mounting hardware will be installed later.

3. Attach the short rubber hose and clamps onto the fuel inlet connection located at the base of the heater.

4. Insert the plastic fuel line all the way into the rubber hose until it bottoms out to prevent air gaps. Tighten both hose clamps securely.

5. Attach the exhaust hose and metal clamp onto the fitting located under the OUTLET end of the heater. Turn metal clamp to the center and tighten securely.

6. Insert the plastic air intake tube through the beveled opening of the small plastic mounting plate. Install the plastic plate and tube onto studs located under the INLET end of the heater.

7. Install lock washers and nuts onto each of the mounting studs and tighten hardware securely.

8. Install gasket to mounting plate.

9. The heater has two service data nameplates. Remove one and reinstall it onto the top of the heater so that it is visible when the heater is installed.

Heater Install10. Position the heat

and fuel line exitscrews and tight

NOTE: Tighten TEKmounting plate and

41


42

n

hose to an open area to the rear or side of the tractor downwards to help drain off condensation and .

le in exhaust hose if necessary to allow for water

can be shortened to a minimum of 8” if required.

ap to exhaust hose.

tube facing towards the rear of the tractor where it fresh, moisture free air.

he sleeper:

sealant around ONLY the four heater mounting

y any sealant around the access hole!

exhaust hose outlet must exit at least 3 feet from ator drains located under the tractor to prevent de poisoning or asphyxiation. FY the two water valves (kazoos) are installed onto drain tubes and are secured with hose clamps.


Exhaust and Combustion Air Intake RoutingIMPORTANT: Correct installation of this heater is necessary to ensure safe and proper operation. BEFORE installing the heater, thoroughly read and understand “Heater Safety Precautions” on page 8 of this manual along with the heater manufacturer’s manual included with the heater.

EXTREME CARE MUST BE TAKEN TO:

• Route the exhaust outlet hose and combustion air intake tube so they cannot be plugged by dirt, water or snow.

• Ensure the exhaust outlet and air inlet do not face into the tractor’s slip stream to prevent “ram air” effect.

• Keep exhaust outlet and air intake hoses a minimum of 12” apart.


• The exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install the protective cap onto the end of the exhaust hose.

• Route the exhaust hose to an open area to the rear or side of the tractor so fumes cannot build up and enter the cab or the combustion air inlet tube to the heater.

• DO NOT mount the exhaust hose to the tractor’s frame. It must be installed to the cab to allow for movement.

Installation

1. Route the exhaustpositioned slightlysecure with clamps

• Drill a 1/8” hodrainage.

NOTE: Exhaust hose

2. Attach metal end c

3. Position air intakecan pick up clean,


• Apply siliconescrews.

• DO NOT appl

DANGER: The correct installation of the exhaust and combustion air intake hoses is extremely important to prevent carbon monoxide poisoning or asphyxiation.

DANGER: Thethe A/C evaporcarbon monoxiALWAYS VERIthe evaporator

43


44

on

cation for the floor level discharge air vent and ng the correct hole saw.

uter louver assembly from the mounting base.

to 2-1/2” hole and secure with supplied screws.

outer louver assembly back into the mounting hat it rotates freely.

heater duct to the discharge outlet hood on the supplied clamp.

to the floor level discharge air vent, cut as nd of the plastic louver vent and secure with

ot used, the protective grille must be installed

cation for the floor level return air grille and ng the correct hole saw.

ir grille into the 2-1/2” hole and secure with

return air duct to the air inlet hood on the heater ied clamp.

ir duct to the return air grille, cut as needed, f the plastic louver vent and secure with supplied

pecial Tools Required

lling discharge air vent and return air grille)

ucts through compartment walls if required)

D2/D4 Heater Duct InstallatiDuct Locations

The heater is equipped with a Return Inlet and Discharge Outlet for attaching the flexible heater duct hoses.IMPORTANT: A return air duct to the heater should be provided for best heating efficiency.

• Return Inlet must be provided to return air to the heater. It is typically mounted at the base of the bunk directly opposite the discharge outlet vent.

• Discharge Outlet should be located at floor level to provide maximum heating comfort in the sleeper. It is typically installed at the base of the bunk on one end.

• Heater ducts should be installed and routed with smooth bends and no kinks to provide maximum airflow.

Installation

Discharge Air

1. Find an appropriate lodrill a 2-1/2” hole usi

• Unsnap rotating o

• Install the base in

• Reinstall rotating base ring. Verify t

2. Attach one end of theheater and secure with

3. Route the heater ductneeded, attach to the esupplied hose clamp.

Return Air

4. If a return air duct is nonto the heater inlet.

5. Find an appropriate lodrill a 2-1/2” hole usi

• Install the return asupplied screws.

6. Attach one end of theand secure with suppl

• Route the return aattach to the end ohose clamp.

CAUTION: • USE SUPPLIED HEATER DUCT HOSE ONLY!

Do not use existing vehicle ducts or outlets. Ducts and outlets must be capable of withstanding a minimum of 300F (148.9C) operating temperatures.

• Adjustable air vent must always be installed so it cannot blow hot air directly at living creatures (people, animals) or objects sensitive to temperature.

• Do not position outlet so that it will blow hot air directly at operator or at thermostat.

• Position air outlet so that it cannot be obstructed.• Use the supplied protective air intake grille on the air inlet

side of the heater to prevent objects from being sucked in.• Do not overtighten duct clamps.• DO NOT lay or bundle the heater ducts with A/C ducts.

They should not touch each other.• Ensure provisions are made for proper air return

ventilation.

S

Drill Motor

2-1/2” Hole Saw (for insta

3” Hole Saw (for routing d

45

n
D2/D4 Heater Duct Installatio

46

ocation for the A/C vents and drill 4-1/4” diameter

e flexible air duct to one of the air discharge outlets d secure with supplied hose clamps.

r duct through the A/C vent hole, cut excess duct as

r louver assembly from the mounting base.

duct to the end of the louver base with band

ase back into 4-1/4” mounting hole and secure .

ter louver assembly back into the mounting base tes freely.

C vent in the same manner.

are installed and routed with smooth bends and no imum airflow.

with large band wraps to prevent excess


Saw (for installing plastic A/C louver vents and ugh compartment walls)

A/C Duct Installation

A/C Vent LocationsThe evaporator is equipped with two air discharge outlets to attach the supplied flexible air ducts. The ducts will be attached to plastic air vents that should be located and installed to provide maximum air circulation in the sleeper. Suggested locations of the air vents:

• MEDIUM (above lower bunk level)

• HIGH (above upper bunk level)

• Alternative Location - LOW (floor level)

NOTE: A/C air ducts and vents are typically routed and installed through closets or storage compartments.

IMPORTANT: Extreme care should always be taken when drilling holes in the various types of material found in sleepers such as plastic, steel, aluminum, and upholstery.

Installation

1. Find an appropriate lholes.

2. Attach one end of thof the evaporator an

3. Route the flexible aineeded.

4. Unsnap rotating oute

5. Attach to flexible airwraps.

6. Push the mounting bwith supplied screws

7. Reinstall rotating ouand verify that it rota

8. Install the second A/

9. Verify flexible ductskinks to provide max

10. Secure flexible ductsmovement.

Drill Motor

4-1/4” diameter Holefor routing ducts thro

47

A/C Duct Installation

48

ses

hecklist

(204-1045)

ls (204-677)

frigerant Hose

ed Clips and Cage

il (204-544)

rings on the nipple assembly are of a specific ze. They should not be removed or replaced.

Fabricating Refrigeration Ho

TK 2000 Assembly SystemThe TK 2000 System is designed for assembly with Multi-Refrigerant hose only.

Assembly Materials C

• Hose Fitting Tool

• Hose Cutting Too

• TK 2000 Multi-Re

• Nipple Assembly

• Appropriately Siz

• PAG Refrigerant O

NOTE: The two black O-rubber compound and si

1. Hose

2. Cage

3. Clips

4. Nipple with internal O-ring

12

3

4

49

es

lips onto the cut end of the hose. Orientation of the performance of the connection. However th clips should have the same orientation.

o slide the clips over the hose at this time will stretched over the hose or fitting later. y damage the clip.

Fabricating Refrigeration Hos

Cut the Hose

1. Cut the hose to proper length with an appropriate cutting tool. Hand-held hose cutter (204-677) has been specially designed for cutting all non-wire reinforced hose, such as TK 2000 Multi-Refrigerant hose. Be sure the cut is made square to the hose length.

Slip on Two Clamps

2. Install two proper- size cthe clips does not affect for ease of assembly, bo

CAUTION: Failure trequire the clips to beThis may permanentl

50

es

e hose. To ensure that the nipple is fully between the cut end of the hose and the Care should be taken to avoid kinking or other ing nipple insertion.

cess oil from the nipple and hose.

Fabricating Refrigeration Hos

Oil the Nipple

3. Lubricate the nipple with a generous amount of the refrigeration or A/C system’s compressor lubricating oil. This MUST be done to lower the force of nipple insertion.

4. Insert the nipple into thinserted, check the gapshoulder on the nipple.damage to the hose dur

NOTE: Be sure to wipe ex

51

ses

the cage arms and into the channels on each arm.

(204-1045 or 204-1128) to close the clips. The itioned squarely on the clip connection points and re during the closing of the clip.

embly, the clasp should be closed between the cage


Snap on the Cage.

5. Snap the cage into the groove on the nipple. The arms should extend over the hose length. When the cage has been carefully installed in the cage grove, the cage will be able to rotate in the grove. This step must be performed to ensure:

• The clips will be located over the O-ring on the nipple.

• The connection will be compatible with the connection’s pressure rating.

Slide the Clips

6. Slide the clips over

Close the Clips

7. Use the fitting tool pliers should be posshould remain squa

NOTE: For easiest assarms.

52

oses

Correct

Incorrect

Fabricating Refrigeration H

Nose of the pliers should be firmly seated under the assembly bump and lock latch.

If the pliers are not kept square during closing the clip, the clasp may have an offset. Use the pliers to correct the clasp alignment.

53

ses

erly Clip

ProperlyInstalled Clip


NOTE: Thermo King recommends adherence to all guidelines, including EPA guidelines concerning the service of refrigerant systems.

CAUTION: TK 2000 Speedy Clip System components should not be reused. Failure to follow these instructions and/or the use of TK 2000 Speedy Clip System hose with fittings supplied by other manufactures could result in sudden or unintended escape of refrigerant gases. Personal injury and/or violations of EPA regulations may occur as a consequence.

ImpropInstalled

54

e Connectionstion and discharge hoses must be secured to the e pre-installed bandwraps exactly as shown in the .

hose installation at the APU compressor fittings. e compressor towards the other A/C system d hose slack inside the APU.

e APU and route the #8 hose into the APU through le and the #10 hose through the lower access hole

ute them through the pre-installed bandwraps ort bracket and then to the compressor. d routing the #8 hose first.

hose to the appropriate length, attach a #10, 45 with service port) and loosely connect to the n the compressor.

e hose to the appropriate length, attach a #8, 45 with service port) and loosely connect to the g on the compressor.

s towards the outside of the APU to remove slack.

sor fittings as necessary to allow hoses to clear engine. Keep both hoses away from fuel strainer, bracket.

ses to the support bracket exactly as shown in the then tighten bandwraps securely Cut off excess h.

tion fittings as specified in the chart.

bowl to 25 in-lb (2.8 N•m) if it was loosened during ol 204-3103 is recommended.

A/C Hose Installation

Installation RequirementsNOTE: Read and understand “Fabricating Refrigeration Hoses” on page 48 for proper hose fabrication requirements. Always use two wrenches while tightening refrigeration fittings.

Tighten all fittings as specified in the chart.

Compressor HosIMPORTANT: The sucsupport bracket with thillustration on page 55

1. Begin refrigeration Work away from thcomponents to avoi

2. Start at the rear of ththe upper access homaking sure you roattached to the suppNOTE: Recommen

• Cut the suction degree fitting (suction fitting o

• Cut the dischargdegree fitting (discharge fittin

3. Gently pull the hose

• Rotate comprescomponents andfuel fittings and

• Position both hoillustration and bandwrap lengt

4. Tighten all refrigera

5. Re-torque pre-filterthe install. Use of to


Hose Fitting Tools (204-1045)

Hose Cutting Tool (204-677)

PAG Refrigerant Oil (203-544)

Torque Wrench

Fitting Size Torque Specifications

#6 (3/8'') 11-13 lb-ft (15-17 N•m)

#8 (1/2'') 15-20 lb-ft (20-27 N•m)

#10 (5/8'') 21-27 lb-ft (28-37 N•m)

#12 (3/4'') 28-33 lb-ft (38-45 N•m)

55

U showing hoses correctly routed and ndwraps to the hose support bracket.

E ON TOP SUCTION HOSE ON BOTTOM


Underside of APsecured with ba

IMPORTANT: Keep hoses away from fuel strainer, fuel fittings and bracket.

DISCHARGE HOS

IMPORTANT: Keep hoses away from fuel strainer, fuel fittings and bracket.

Hoses shown correctly routed and secured with bandwraps to hose support bracket.

Remove bottom panel

Remove excess length after tightening

56

seroute the #8 discharge hose to the condenser coil:

to the appropriate length, attach a #8 fitting and e #8 discharge fitting located near the top of the il.

eceiver Drierse and fitting and attach onto the #6 liquid line fitting r:

se down through the 3” access hole in the tractor floor r drier.

to the appropriate length, attach a #6 fitting and e OUTLET end indicated by arrow on the receiver

eceiver Drierse and fitting and attach onto the #6 fitting on the

se to the receiver drier.

to the appropriate length, attach a #6 fitting and e INLET end on the receiver drier.

gs as specified in the chart.

ure APU side panel.

pan will be reinstalled in a later step.


Installation RequirementsNOTE: Read and understand “Fabricating Refrigeration Hoses” on page 48 for proper hose fabrication requirements. Always use two wrenches while tightening refrigeration fittings.

Tighten all fittings as specified in the chart.

Compressor to Evaporator6. From the APU, route the #10 suction hose up through the 3” access

hole in the tractor floor to the evaporator:

• Cut the hose to the appropriate length, attach a #10 fitting and connect to the #10 suction fitting on the evaporator.

APU to Conden7. From the APU, r

• Cut the hoseconnect to thcondenser co

Evaporator to R8. Fabricate a #6 ho

on the evaporato

• Route the hoto the receive

• Cut the hoseconnect to thdrier.

Condenser to R9. Fabricate a #6 ho

condenser coil:

• Route the ho

• Cut the hoseconnect to th

10. Tighten all fittin

11. Reinstall and sec

NOTE: The bottom


Hose Fitting Tools (204-1045)


PAG Refrigerant Oil (203-544)

Torque Wrench

Fitting Size Torque Specifications

#6 (3/8'') 11-13 lb-ft (15-17 N•m)

#8 (1/2'') 15-20 lb-ft (20-27 N•m)

#10 (5/8'') 21-27 lb-ft (28-37 N•m)

#12 (3/4'') 28-33 lb-ft (38-45 N•m)

57

st be secured to the refrigerant hose support lustration on page 55.


IMPORTANT: The suction and discharge hoses mubracket with the cable ties exactly as shown in the il

Compressor Hose Connections

58

eck Procedures

pump valve, switch off the pump, checking that the r the vacuum pump does not exceed 2000 microns in e minutes. If vacuum level exceeds 2000 microns tes, and continues to rise, proceed to the Leak Check ion below.

remains below 2000 microns for 5 minutes the system eady to be filled with refrigerant.

and valves and remove evacuation equipment.

rocedures4a to the unit until bottle pressure is reached.

check the system with an electronic leak detector.

nd, recover leak check charge.

and re-evacuate system.

A/C System Evacuation and Leak Ch

System Evacuation Procedures

NOTE: The oil in the evacuation station vacuum pump should be changed after each use.

IMPORTANT: Always use recommended vacuum equipment. Before each use, check that there are no leaks in the vacuum equipment either in the pump itself or in the hoses.

1. Connect the gauge manifold to the suction and discharge service ports of the APU’s compressor.

2. Connect the service line of the gauge manifold to the vacuum pump and micron gauge.

3. Open the gauge manifold and vacuum pump valves and gauge manifold hand valves.

4. Start the vacuum pump and evacuate until system reaches 500 microns.

5. Once the system reaches 500 microns, continue evacuation forone additional hour.

NOTE: While the system is being evacuated, and to save installation time, continue on to the electrical installation beginning with “Control Box and Main Harness Installation” on page 60. Return and complete this procedure later.

6. Close the vacuumgauge reading fothe following fivbefore five minuProcedures sect

7. If vacuum level is leak free and r

8. Close manifold h

Leak Check P1. Add vapor R-13

2. Thoroughly leak

3. If leak(s) are fou

4. Repair any leaks


Thermo King Evacuation Station (P/N 204-725) Recommended

Evacuation Station Operation and Field Application Instructions (TK-40612)

Electronic Leak Detector (204-756)

Gauge Set with R134a Adapters

59

eck Procedures
A/C System Evacuation and Leak Ch

60

llation

lation any electrical connections, confirm the s are not connected to the battery.

ngths should be doubled up and secured T THE WIRE HARNESSES!

e pins for straightness before attempting to nce is felt when mating the connector:

nt. Exercise care when mating the

ide the truck and remove the cover.

rness from APU up into sleeper through 3” into the control box.

to mating connector (J14) on interface

mating connector (J5) on interface board.

wire with the terminal ring onto interface CH (J16) and torque to 18 lb-in (2 N•m).

re terminal ring must be positioned and tightened properly or the unit will not

to mating connector (J6) on interface board.

A, COILSEN, COILSEN-RTN) will be or on A/C evaporator harness that will be

is for Standby Truck Integration Switch

l ring onto interface board power stud (J15 N•m).

inal ring must be positioned correctly on decal located on control box cover.

Control Box and Main Harness Insta

Control Box LocationThe box can be mounted horizontally or vertically. Make sure the location chosen allows access for:

• Installation of wiring

• Servicing of interface board components

• Operation of the reset switch.

NOTE: DO NOT install the control box at this time. It will be installed AFTER all the TriPac electrical harnesses have been connected.

DPF Units Only - Small Engine Control Module (SECM) and HarnessesInstall the SECM and harnesses now. Refer to TK 55727-19-IM for details.

Power Inverter Option Only Install the power inverter now. Refer to TK 55855-19-IM for details.

Hourmeter Option OnlyInstall the hourmeters and harness now. Refer to TK 55701-19-MS for details.

Main Harness InstalIMPORTANT: Before makingHeater and APU battery cable

NOTE: Excessive harnesses lewith band wraps. DO NOT CU

NOTE: Always check the malmate connectors. If any resistarecheck the male pin alignmeconnection.

1. Position the control box ins

2. Route Main Electrical Haaccess hole in the floor and

3. Connect 20-pin connector board.

4. Connect 6-pin connector to

5. Attach the separate CH-01board ground stud labeled

IMPORTANT: The CH-01 wicorrectly onto the ground studoperate.

6. Connect 10-pin connector

7. 4-pin connector (7CL, 7CLattached to mating connectinstalled in a later step.

8. 2-pin connector (SBY, 2A)(OPTION).

9. Attach 2 wire with termina2) and torque to 18 lb-in (2

IMPORTANT: The 2 wire termonto the power stud as shown

61

stallation
Control Box and Main Harness In

62

on

ly - Exhaust Monitor and Switchonitor and regeneration switch now. Refer to TK ails.

HMI Controller Installati

HMI Controller LocationChoose a location inside the tractor’s sleeper for the HMI controller that is easily accessible and visible from the drivers bunk.

Two separate wire harnesses need to be routed and connected to the HMI:

• HMI Harness - from control box to the HMI.

• The HMI should be visible and mounted away from windows, air vents, out of direct sunlight to accurately measure air temperature.

Installation

Locate the HMI Controller Harness with the 8-pin connectors on each end supplied loose in the installation kit.

1. Connect to the HMI (J34) connector on the main controller board inside the control box.

2. From the control box, route the harness behind the interior walls (if applicable) to the location chosen to install the HMI controller.

3. Unsnap the rear mounting base from the controller and route the harness connector through the access hole.

• Position and level the mounting base and install securely.

4. Push the connector firmly into the rear of the controller and snap the controller back onto the mounting base.

DPF Units OnRegenerationInstall the exhaust m55727-19-IM for det


Level

Drill Motor

Drill Bits

63

n
HMI Controller Installatio

64

ion
D2/D4 Heater Wiring Installat
Installation

Locate the heater harness supplied in the kit. Remove the two small plastic bags attached to the harness containing the fuel pump electrical connector components and the in-line fuse assembly. Retain these for installation later.

1. Connect the16-pin connector to the heater:

• use a large bladed screwdriver to pull the locking tab out(to unlock) from the connector body.

• connect the two 16-pin connectors together.

• push locking tab back in (to lock) the connector body.

2. Route the heater control harness connectors into the control box, but DO NOT make any connections to the interface board at this time. They will be connected later after the Heater Start-Up Procedures are completed.

3. The 8-pin connector (with 4 wires) is used for diagnostic purposes only.

4. Route the fuel pump harness out of the sleeper through the 3” access hole. It will be assembled and connected to the fuel pump in a later step.


Wire Cutters

Terminal Crimping Tool

65

tion
D2/D4 Heater Wiring Installa

66

lation
D2/D4 Heater Wiring Instal
Remote Temperature Sensor - D4 Heater Only

Installation1. Install the Espar Remote Temperature Sensor next to the HMI and route

the sensor harness down to the control box the same way the HMI harness was routed.

2. Locate the 14-pin heater harness connector. This connector should not be connected to the interface board at this time.

3. Carefully remove approximately 203 mm (8.00 in.) of both the outer and inner harness sleeving from the connector end of the Espar Heater Harness to gain access to the 8 individual wires.

4. Measure approximately 102 to 152 mm (4.00 to 6.00 in.) from the connector and splice the following two wires together using butt splice connectors:

• Brown/White wire from heater harness to Black wire from the sensor harness.

• Grey wire from heater harness to RED wire from the sensor harness.

• Seal the splice the connections.

The 14-pin heater connector should not be connected to the interface board at this time. It will be connected later after the Heater Start-Up Procedures are completed.

67

tion
D2/D4 Heater Wiring Installa

68

ly components. Refer to TK 55727-19-IM for details.

s and harnesses

sensor

sducer

d air pressure hoses

A/C Wiring Installation

InstallationNOTE: Excessive harnesses lengths should be doubled up and secured with band wraps. DO NOT CUT THE WIRE HARNESSES!

1. Route the A/C harness to the control box.

2. Connect 4-pin connector (7CL, 7CLA, COILSEN, COILSEN-RTN) to the mating connector located on the main harness installed earlier.

3. Connect 6-pin connector to AC COND connector (J2).

4. Connect 4-pin connector to AC EVAP connector (J1).

5. Route harnesses (7CF, 7CF-RTN) and (7CL, 7CLA) out of the sleeper through the 3” access hole towards the condenser coil.

6. Attach connector (7CL, 7CLA) to the receiver drier binary switch.

7. Attach connector (7CF, CH-08) to the condenser fan harness.

8. Install control box securely with TEK screws in location chosen earlier.

DPF Units OnInstall the following

• Valve box

• Battery cable

• Ambient air

• Pressure tran

• Air intake an

69

A/C Wiring Installation

70

Switch (Option)

y switch now. Refer to TK 55727-19-IM for details.

Standby Truck Integration Harness with

Installation

Access the tractor’s ignition switch wires at rear of the switch:

a. Turn ignition switch to the “ACCESSORY” position and use a digital meter to locate a wire connection with NO POWER (0 Vdc).

b. Turn ignition switch to the “ON” position and re-check for voltage at the same wire connection tested earlier. If voltage is present, this is where the IGN wire will be connected.

Typically the standby switch is installed in the dashboard in a location that is easily accessible for the driver.

1. Remove dash panel (if required). Mark and drill 1/2” hole.

2. Install the standby switch, nameplate and nut. Confirm the 2A wire on the switch is facing UP and then tighten the nut securely.

3. Connect IGN wire with in-line fuse to:

4. Route the standby switch harness to the control box and connect the 2-pin connector (SBY and 2A) to the mating pigtail connector found on the main harness installed earlier.

DPF Units OnlInstall the regenerationSpecial Tools Required

Digital Meter (204-615)

Drill Motor

1/2” Drill Bit

WIRE VEHICLE CONNECTION

IGN

“ON” circuit of ignition switch

or

“ON” circuit of fuse panel

71

Switch (Option)

72

out Switch (Option)

lyon switch now. Refer to TK 55727-19-IM for details.


Installation

Access the tractor’s ignition switch wires at rear of the switch:

a. Turn ignition switch to the “ACCESSORY” position and use a digital meter to locate a wire connection with NO POWER (0 Vdc).

b. Turn ignition switch to the “ON” position and re-check for voltage at the same wire connection tested earlier. If voltage is present, this is where the IGN wire will be connected.

1. Connect IGN wire with in-line fuse to:

2. Route the standby harness to the control box and connect the 2-pin connector (SBY and 2A) to the mating pigtail connector found on the main harness installed earlier.

DPF Units OnInstall the regeneratiSpecial Tools Required

Digital Meter (204-615)

WIRE VEHICLE CONNECTION

IGN

“ON” circuit of ignition switch

or

“ON” circuit of fuse panel

73

ut Switch (Option)
Standby Truck Integration Harness witho

74

n

R PLATE (10-379)

) 5 bolt mounting flange

mounting flange and block off plate on tractor’s ck off plate and clean surface area of all dirt,

-379 (counter sunk holes facing up) and the e supplied screws and torque to 90 lb-in. .

e fuel supply tube is 24” and heater fuel supply

PU diesel fuel supply tube 2” shorter than fuel

eater fuel supply tube 3” shorter than fuel tank er fuel supply tube is identified by not having a

ardware to top of the pickup tube assembly.

pproximately 12” apart then squeeze pickup d insert tubes and bushing into hole of adapter

d insert into hole of adapter plate.

er on underside of adapter plate, thread nut onto tighten.

upplied fuel pump bracket for fuel heater.

be as needed to facilitate fuel line connections 16 to 18 ft-lb. (21 to 24 N•m).

g nameplates onto fuel tanks in a visible area

Fuel Pickup Tube Installatio

PREFERRED INSTALLATION WITH OPTIONAL ADAPTE

For OEM fuel tanks equipped with an auxiliary fuel level sender (FLS

Installing the Fuel Pickup Tube & Adapter PlateNOTE: Some OEM’s offer a fuel tank option which provides three auxiliary fuel fitting connections. With this option, the fuel pickup tube and adapter plate are not needed. Simply route and connect the APU’s fuel supply and return lines and the heater’s fuel supply line to these fittings. Always check your fuel tank for these fittings before installing the fuel pickup tube or adapter plate.

IMPORTANT INSTALLATION TIPS

• Identify and mark APU FUEL SUPPLY pickup tube for reference later.

• Remove protective caps from ends of pickup tubes prior to installation.

• Do not apply any type of sealant material to fuel pickup assembly. Doing so will result in plugged fuel lines.

Installation1. Locate auxiliary FLS

fuel tank. Remove blogrease, etc.

2. Install adapter plate 10gasket. Secure with th(10.2 N•m) maximum

3. The APU diesel engintube is 23”.

• Measure and cut Atank diameter.

• Measure and cut hdiameter. The heatfitting.

4. Loosen and slide the h

5. Spread pickup tubes atubes back together anplate.

6. Tip back-up washer an

• With back-up washbushing and hand

• OPTION - Install s

• Position pickup tuand tighten nut to

7. Install supplied warninnear fuel cap.

DANGER: Use caution when working in or around the area of the diesel fuel tank. Diesel fuel vapors are potentially explosive. Do not smoke while working near the diesel fuel tank.


Tape Measure

Tubing Cutter

Torque Wrench

75

PLATE (10-379) 5 bolt mounting flange

Fuel Pickup Tube Installation

PREFERRED INSTALLATION WITH OPTIONAL ADAPTERFor OEM fuel tanks equipped with an auxiliary fuel level sender (FLS)

Adapter Plate

76

UEL TANK TIPSUPPLY pickup tube for reference later.

from ends of pickup tubes prior to

roximately 12” apart.f sealant material to fuel pickup assembly. lugged fuel lines.s in fuel tank BEFORE drilling any holes.

ed with pickup tube) onto tractor’s fuel tank s. Remove template from tank.rill: s first with step reamer.le next with hole saw.ush the tank to remove any chips. supply tube is 24” and the heater fuel

iesel fuel supply tube 2” shorter than fuel

fuel supply tube 3” shorter than fuel tank l supply tube is identified by not having a

to top of pickup tube assembly.

imately 12” apart then squeeze pickup rt tubes and bushing into hole of adapter

ert it to fuel tank hole. underside of fuel tank hole, thread nut onto n.ed fuel pump bracket for fuel heater.needed to facilitate fuel line connections 18 ft-lb. (21 to 24 N•m).

eplates onto fuel tanks in a visible area

Fuel Pickup Tube InstallationALTERNATIVE INSTALLATION BY DRILLING HOLE IN F

Installing the Fuel Pickup TubeNOTE: Some OEM’s offer a fuel tank option which provides three auxiliary fuel fitting connections. With this option, the fuel pickup tube and adapter plate are not needed. Simply route and connect the APU’s fuel supply and return lines and the heater’s fuel supply line to these fittings. Always check your fuel tank for these fittings before installing the fuel pickup tube or adapter plate.

IMPORTANT INSTALLATIONIdentify and mark APU FUEL S

• Remove protective capsinstallation.

• Spread pickup tubes app• Do not apply any type o

Doing so will result in p• Check for internal baffle

Installation1. Tape paper template (suppli

and center punch three hole2. Drill a 1/4” pilot hole then d

• 1/2” diameter outer hole• 1-1/4” diameter inner ho• Thoroughly clean and fl

3. The APU diesel engine fuelsupply tube is 23”. • Measure and cut APU d

tank diameter.• Measure and cut heater

diameter. The heater fuefitting.

4. Loosen and slide hardware

5. Spread pickup tubes approxtubes back together and inseplate.

6. Tip back-up washer and ins• With back-up washer on

bushing and hand tighte• OPTION - Install suppli• Position pickup tube as

and tighten nut to 16 to

7. Install supplied warning namnear fuel cap.

DANGER: Use caution when working in or around the area of the diesel fuel tank. Diesel fuel vapors are potentially explosive. Do not smoke while working near the diesel fuel tank.

DANGER: Before drilling into a fuel tank, drain all diesel from the tank. Use nitrogen or an inert gas to purge the diesel fuel vapors from the tank. Keep the diesel tank filled with inert gas while drilling.

DANGER: Use extreme caution when drilling into a diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion.


Tape Measure

Drill Motor

Step Reamer Bit

1-1/4” Hole Saw

Tubing Cutter

Heavy Grease

Torque Wrench

77

ion IN FUEL TANK

Fuel Pickup Tube InstallatALTERNATIVE INSTALLATION BY DRILLING HOLE

78

stallation

e connection to the outlet end of the fuel pump lied hose clamp.

line (installed earlier on the heater) to the fuel th. Insert the fuel line into the rubber hose tts up tight with the fuel pump’s outlet pipe ith supplied hose clamp.

st be installed correctly to prevent air bubbles

the pickup tube, to fuel pump, to heater should ntinuous rise.

utter or utility knife to cut plastic fuel lines. Do tter as this will pinch the plastic fuel line closed.

the fuel pick-up supply to the inlet end of the fuel h supplied hose clamp. NOTE: The heater fuel identified by not having a fitting.

Heater Fuel Pump and Fuel Line In

Installation

Fuel Pump InstallationIMPORTANT: Proper mounting angle of the fuel pump is necessary to allow any air or vapor in the fuel lines to pass through the pump rather than cause a blockage (Detail s A and B).

The fuel pump can be installed using either the L-bracket or the fuel tank mounting bracket (both supplied).

L-Bracket Installation1. Choose a protected mounting location close to the fuel pick-up tube

and heater.

2. Install the fuel pump into the supplied rubber mounting clamp and attach the L-bracket.

3. Position the fuel pump at a 15 to 35 degree angle with the outlet end facing up (outlet end has connector and smaller barb fitting) and secure the clamp and bracket securely (Detail A).

Fuel Tank Bracket Installation1. Loosen the fuel pickup tube nut and position the supplied fuel pump

bracket under the nut then re-tighten the nut to 16 to 18 ft-lb. (21 to 24 N•m). NOTE: The bracket goes under the nut, not under the washer or rubber gasket.

2. Install the fuel pump into the supplied rubber mounting clamp and attach the rubber clamp to the tank mounted bracket securely.

Fuel Lines1. Attach the rubber hos

and secure with supp

2. Route the plastic fuelpump and cut to lengconnection until it bu(Detail B). Secure w

• The fuel line mu(DETAIL B).

• The fuel line frombe routed at a co

• Only use a hose cnot use a wire cu

3. Attach fuel line frompump and secure witpickup supply tube is


Utility Knife


79

tallation
Heater Fuel Pump and Fuel Line Ins

80

APU Fuel Line Installation

Installation

NOTE: Be sure to connect the APU’s fuel supply line to the fuel SUPPLY pickup tube connection identified and mark earlier.

1. Route the APU fuel supply line to the SUPPLY connection of the fuel pickup tube, cut to proper length and attach with compression fittings.

2. Route the APU fuel return line to the RETURN connection of the fuel pickup tube, cut to proper length and attach with compression fittings.

3. Route and secure all fuel lines with adequate clamps.


Utility Knife

81

APU Fuel Line Installation

82

n

s

.

radiator and engine. Keep for re-use.oolant hose on tractor’s engine: hose and install pipe fittings, elbow, tee

nnect and route a new coolant hose back to ated on the APU.

coolant hose on the tractor’s engine:t hose and install pipe fittings, elbow, tee

nect and route a new coolant hose back to d on the APU precooler.

ving on all coolant hoses and secure

T hand valve (tractor inlet, next to water e is left open, coolant will be sitting on top not allow the TriPac engine to bleed air. of air later by following the “A/C System rt-up Procedures” on page 100.rlier back into the tractor’s radiator.r’s engine at this time.eplate in a visible area near the tractor’s

l Tools Required

Tractor Coolant Hose InstallatioPREFERRED INSTALLATION

APU Coolant Hoses Tee’d Directly Into Tractor’s Heater Hose

NOTE: Skip this step if your APU has the Closed Loop Cooling Option

Coolant Hose Routing and ConnectionsEach coolant hose installation will be different. Carefully review the tractor’s engine cooling system to determine the best method for installing the cooling hoses and hand valves. Consult tractor dealer or OEM for assistance in identifying correct coolant hoses or engine fittings required for proper installation.

NOTE: All APU coolant hoses should be installed in such a way as to allow the hand valves to isolate the APU cooling system from the tractor’s cooling system. This hand valve must be located as close to the tractor’s engine as possible.Theory of Operation

With the tractor’s engine shut off, and the TriPac APU engine operating, warm coolant is circulated from the APU engine up to the tractor’s engine and then back to the APU engine. This keeps the tractor’s engine warm allowing for easier cold starts.

• When the TriPac APU engine is running and coolant temperature reaches normal operating temperature of 180 F (82 C), the thermostat will open allowing hot coolant to flow from the APU OUTLET fitting forward to the tractor’s engine.

• Hot coolant enters the tractor’s engine block through an INLET fitting typically located near the water pump.

• Hot coolant circulates through the tractor’s engine block and exits an OUTLET fitting typically used for the heater.

• Warm coolant then returns to the TriPac APU and enters the INLET fitting.

• Warm coolant circulates through the APU’s engine block to absorb heat before being pumped back out to the tractor’s engine.

• Hand valves are installed to allow the APU’s cooling system to be isolated from the tractor’s cooling system to allow for component servicing.

Installation

1. Drain coolant from tractor’s2. Locate HEATER INLET c

• Cut tractor’s heater inletfitting and hand valve.

• From the hand valve, cothe OUTLET fitting loc

• CLOSE hand valve.3. Locate HEATER OUTLET

• Cut tractor’s heater outlefitting and hand valve.

• From shutoff valve, conthe INLET fitting locate

• OPEN hand valve.4. Install protective plastic slee

coolant hoses with clamps.5. Make sure the APU OUTLE

pump) is closed. If this valvof the TriPac thermostat and

NOTE: The system will be bledCharging and APU Engine Sta

• Add coolant removed ea• DO NOT start the tracto

6. Install supplied coolant namcoolant fill cap.

Specia

Utility Knife

Pipe Thread Sealer

83

ion

oses

Tractor Coolant Hose InstallatPREFERRED INSTALLATION

APU Coolant Hoses Tee’d Directly Into Tractor’s Heater H

NOTE: If the Arctic Block Temperature Sensor Option is to be installed, it should be installed at this time. See “Arctic Switch (Option)” on page 86.

84

n

n Tractor’s Engine

n.

s radiator and engine. Keep for re-use.es as a guide to locate an INLET plug on pump. Remove plug and:rt section of coolant hose and hand valve.stall a hose fitting and route a new coolant ET fitting located on the APU.

es as a guide to locate an OUTLET plug on lug and:rt section of coolant hose and hand valvestall a hose fitting and route a new coolant fitting located on the APU precooler.

eving on all coolant hoses and secure hoses

ET hand valve (tractor inlet, next to water e is left open, coolant will be sitting on top

d not allow the TriPac engine to bleed air.d of air later by following the “A/C System art-up Procedures” on page 100.arlier back into the tractor’s radiator.or’s engine at this time.eplate in a visible area near the tractor’s

l Tools Required

Tractor Coolant Hose InstallatioALTERNATIVE INSTALLATION

Separate APU Coolant Hoses Attached Directly To Threaded Fittings Located O

NOTE: Skip this step if your APU has the Closed Loop Cooling Optio

Coolant Hose Routing and ConnectionsEach coolant hose installation will be different. Carefully review the tractor’s engine cooling system to determine the best method for installing the TriPac APU cooling hoses and hand valves. Consult the tractor dealer or OEM for assistance in identifying correct coolant hoses or engine fittings required for proper installation.

NOTE: All APU coolant hoses should be installed in such a way as to allow the hand valves to isolate the APU cooling system from the tractor’s cooling system. This hand valve must be located as close to the tractor engine as possible.Theory of OperationWith the tractor’s engine shut off, and the TriPac APU engine operating, warm coolant is circulated from the APU engine up to the tractor’s engine and then back to the APU engine. This keeps the tractor’s engine warm allowing for easier cold starts.

• When the TriPac APU engine is running and coolant temperature reaches normal operating temperature of 180 F (82 C), the thermostat will open allowing hot coolant to flow from the APU OUTLET fitting forward to the tractor’s engine.

• Hot coolant enters the tractor’s engine block through an INLET fitting typically located near the water pump.

• Hot coolant circulates through the tractor’s engine block and exits an OUTLET fitting typically used for the heater.

• Warm coolant then returns to the TriPac APU and enters the INLET fitting.

• Warm coolant circulates through the APU’s engine block to absorb heat before being pumped back out to the tractor’s engine.

• Shutoff valves are installed to allow the APU’s cooling system to be isolated from the tractor’s cooling system to allow for component servicing.

Installation

1. Drain coolant from tractor’2. Use the tractor’s heater hos

the engine before the water• Install hose fittings, sho• From the hand valve, in

hose back to the OUTL• CLOSE hand valve.

3. Use the tractor’s heater hosthe engine block. Remove p• Install hose fittings, sho• From the hand valve, in

hose back to the INLET• OPEN Hand Valve.

4. Install protective plastic slewith adequate clamps.

5. Make sure the APU OUTLpump) is closed. If this valvof the TriPac thermostat an

NOTE: The system will be bleCharging and APU Engine St

• Add coolant removed e• DO NOT start the tract

6. Install supplied coolant namcoolant fill cap.

Specia

Utility Knife

Pipe Thread Sealer

85

on

On Tractor’s Engine

Tractor Coolant Hose InstallatiALTERNATIVE INSTALLATION

Separate APU Coolant Hoses Attached Directly To Threaded Fittings Located

NOTE: If the Arctic Block Temperature Sensor Option is to be installed, it should be installed at this time. See “Arctic Switch (Option)” on page 86.

86

to mating 2-pin connector (WT2, WT2-RTN) .

nd secure all wires adequately with supplied band

for leaks and reinstall sleeving on coolant hose.

position to prevent the APU or tractor’s engine

and tractor’s engine coolant system should be at in and eyes.

Arctic Switch (Option)

Installation Procedures1. Locate Arctic Option harness (WT2,WT2-RTN) band wrapped inside

unit, near top, right side of frame. Un-band and route harness and connector out of unit, through hole in right side of frame, behind pre-cooler coil. Secure connector to anchor provided on outside of panel as shown in illustration.

2. Locate INLET coolant hose and measure approximately 6.00 in. (152.4 mm) out from APU.

3. Slide sleeving away to expose coolant hose and mark 3.00 in. (76.2 mm) to be removed.

4. Clamp off each side of coolant hose with a hose crimper to prevent excessive coolant loss.

5. Use a hose cutter and remove 3.00 in. (76.2 mm) section of coolant hose.

6. Install tube and sensor assembly with hose clamps.

IMPORTANT: When tube and sensor assembly is installed horizontally sensor must face down, when installed vertically sensor must face towards APU (DETAIL A).

7. Plug sensor harness located outside APU

8. Provide a drip loop awraps.

9. Operate unit, check

CAUTION: Before installing the Arctic option, set APU and vehicle electrical controls to the OFFfrom starting unexpectedly.

CAUTION: Always wear safety goggles and work gloves when working with antifreeze. The APUambient temperature to prevent hot, pressurized coolant from causing painful burns to exposed sk

87

Arctic Switch connector shown secured to anchor outside unit.

Arctic Switch (Option)

88

ns
Heater Fuel Pump Connectio
Heater Fuel Pump Connections

1. Route the heater fuel pump harness down to the fuel pump and cut the wires to the correct length.

• Strip wire ends, slide on rubber sealing boots, attach pin terminals securely with crimping tool.

• Insert pin terminals into connector body until they lock in place.

NOTE: The pump is not polarity sensitive. The wires can be installed in either location of the connector body.

• Snap locking cover closed on connector body.

• DO NOT connect the fuel pump harness to the fuel pump at this time. The fuel pump harness will be attached later after the fuel pump has been primed.


Wire Cutters

Terminal Crimping Tool

CAUTION: To prevent the APU from starting unexpectedly, set all electrical controls to the OFF position BEFORE connecting wires to battery.

89

ions

is time.

Heater Fuel Pump Connect

NOTE: DO NOT connect these to the interface board at th

NOTE: DO NOT connect to fuel pump at this time.

90

ctionsTERY CABLE rom the excess positive cable) that reaches e terminal to fuse holder and strip 1/2 to 3/4 sulation from cable ends. and terminal ring with small hole onto end

al ring firmly to cable. and terminal ring with large hole onto ch terminal ring firmly to cable.ing to cover exposed wires on terminal

n to shrink tubing in place. d with small hole terminal ring followed by e onto the fuse holder stud and only hand

d with large hole terminal ring connector ITIVE (+) connection and tighten securely. 03-524) onto the battery’s connection.

ABLEom TriPac to tractor’s negative battery, cut o 3/4 in. (13 to 19 mm) of insulation from

ink tubing and terminal ring onto end of ring firmly to end of cable.ing to cover exposed wires on terminal ring rink tubing in place.rminal lug onto the battery’s NEGATIVE

ten securely.03-524) onto the battery’s connection.

holder and place fuse onto the studs and on battery cables lugs, then reinstall nuts. in-lb (13.5 N•m) and close the fuse holder

Fuse Holder and APU Battery ConneDPF Units OnlyRoute and connect the battery cables to the fuse holder, valve box and DPF now. Refer to TK 55727-19-IM for details.

Power Inverter Option OnlyRoute and connect the power inverter cables to the battery and fuse holder now. Refer to TK 55855-19-IM.

Important Battery Cable Installation InformationIMPORTANT: Do not attach both the positive and the negative cables to a single battery. For best results, attach the positive cable to the first battery and the negative cable to the last battery as shown.1. FUSE HOLDER

• Mount fuse holder securely to battery box structure with (installer supplied) 1/4-20 hardware within 12.0 inches (304.8 mm) of positive battery terminal. It is not acceptable to leave fuse holder loose or tied to other cabling.

• DO NOT install fuse at this time.

2. POSITIVE BATTERY CABLE AND VOLTAGE SENSING WIRE• Route positive cable with voltage sensing wire from TriPac to fuse

holder.• Cut battery cable to length and strip 1/2 to 3/4 in. (13 to 19 mm) of

insulation from cable end. • Slide heat shrink tubing and terminal ring with small hole onto end

of cable. Attach terminal ring firmly to cable.• Position heat shrink tubing to cover exposed wires on terminal ring

and use a heat gun to shrink tubing in place.• Install cable onto fuse holder stud and only hand tighten nut.• Cut voltage sensing wire to length, strip end, attach in-line fuse

with splice connector.• Slide heat shrink tubing and terminal ring onto other end of in-line

fuse. Attach terminal ring firmly to wire.• Position heat shrink tubing to cover exposed wires on terminal ring

and use a heat gun to shrink tubing in place. This wire will be attached in the step 3.

3. SHORT POSITIVE BAT• Fabricate short cable (f

from the battery positivin. (13 to 19 mm) of in

• Slide heat shrink tubingof cable. Attach termin

• Slide heat shrink tubingother end of cable. Atta

• Position heat shrink tubrings and use a heat gu

• Install battery cable enthe voltage sensing wirtighten nut.

• Install battery cable enonto the battery’s POS

• Apply Superlube (PN 2

4. NEGATIVE BATTERY C• Route negative cable fr

to length and strip 1/2 tcable end.

• Slide supplied heat shrcable. Attach terminal

• Position heat shrink tuband use a heat gun to sh

• Install negative cable te(-) connection and tigh

• Apply Superlube (PN 2

5. FUSE• Remove nuts from fuse

top of sensing wire and• Tighten the nuts to 120

cover securely.

91

ections

ith band wraps and beam flange s!

Fuse Holder and APU Battery Conn

CAUTION: Route and secure the TriPac battery cables wfasteners so they do not cross or rub on existing cable

92

p

ness switch to the “ON” position.

operate the fuel pump (ON/OFF/ON/OFF) to

perate for approximately 5 minutes to bleed air

l pump longer then 5 minutes will cause the white smoke when operated.

system for leaks.

ess switch to the “OFF” position. Disconnect the negative battery connections.

ng harness connector from the heater fuel pump.

l pump harness onto the heater fuel pump.

Priming the Heater Fuel Pum

Priming the Heater Fuel System

The heater uses a pulse style fuel pump. You must use the heater priming harness to operate the fuel pump to prime the system. Applying continuous power to the pump will not work.

NOTE: Verify there is a sufficient amount of fuel in the fuel tank.

1. Attach the Heater Priming Harness connector to the heater fuel pump.

2. Attach the alligator clips to the battery:

3. Turn the priming har

4. The flasher unit will prime the system.

5. Allow the system to ofrom the fuel lines.

NOTE: Running the fueheater to emit excessive

6. Check fuel lines and

7. Turn the priming harnpositive and then the

8. Disconnect the primi

9. Attach the heater fue


Heater Priming Harness (204-1144)

Wire Battery Connection

RED POSITIVE

BLACK NEGATIVE

93

p
Priming the Heater Fuel Pum

94

ures

iagnostic Unithe 2-pin connector (Red, Brown) heater power wire er in the control box) to mating connector (J9) on the .

ect the 14-pin connector at this time. It will be r the Heater Start-Up Procedure have been completed.

apter harness to the Diagnostic Tool.

pin diagnostic connector to the mating connector located arness inside the sleeper near the heater.

emaining adapter harness connectors shown in the t used.

Heater Start-Up Proced

Heater Start-Up ProceduresNOTE: See Operating and Diagnostic Manual TK 53024-19-OD for further diagnosis and service procedures if needed.

Diagnostic UnitThe diagnostic unit is used to read out, display and delete faults stored in the heater's electronic control box. It may also be used to start and run the heater.

• The test duration is limited to a maximum of 120 minutes.

• The electronic control box can store up to 5 faults.

• The current fault is displayed as “AF” and a 2-digit number and is always written in memory location F1.

• The stored faults “F1” to “F5” can be queried.

Connect the D1. Connect only t

(installed earliinterface board

DO NOT connconnected afte

2. Connect the ad

3. Connect the 8-on the heater h

NOTE: The two rillustration are no


Heater Diagnostic Tool (204-1143)

95

es
Heater Start-Up Procedur
NOTE: DO NOT connect at this time.

96

s

our minute start up process.

slow and heater will ignite.

will ramp up to high boost mode.

check the following:

e hoses are installed and functioning correctly.

ut of the heat duct inside the sleeper.

.

a four minute cool-down mode.

nit from the heater harness and connect the 14-pin to the interface board (J13).

Heater Start-Up Procedure

Perform the Start-UpAutomatic DetectionFive seconds after the diagnostic tool has been connected to the heater using the adapter cable, the automatic detection starts to determine the type of heater to which the diagnostic unit is connected.

NOTE: If the automatic detection was successful, if necessary, the heater is briefly started and then switches off again.

• Display until the automatic detection is completed.

• Heater Icon will display when heater has been detected.

Confirm flashing symbol with

Possible Displays:

• if no errors/faults exist go to Heater Start-up.

• if errors/faults exist go to Clearing Faults.

• Communication error. Go to Unable to Perform the Diagnosis

Heater Start-UpThe heater will begin a f

• Blower will start

• Heat and blower

With the heater operating

• Exhaust and intak

• Heat is blowing o

Press to stop heater

• Heater will begin

Disconnect Diagnostic Uheater harness connector

97

s

the fault memory again

and

ry and as a result, at the same time lock

F5

cel control box lock by pressing

nfirm deletion.

eleted and the control box is

Start-Up or Diagnosis.

Heater Start-Up Procedure

Clearing FaultsDisplay current fault in fault memory

Press and simultaneously to display active or current faults in memory.

Display: e.g. AF: 12

Display fault memory F1 – F5

Press or to display any faults in memory.

Display: e.g. F1: 20

Record all fault codes. Refer to the diagnostic manual for an explanation of fault code diagnosis.

Display current fault in

Simultaneously press

Display: e.g. AF: 12

Delete the fault memocancel the control box

Current fault or fault F1 –

Clear all faults and can

dEL will display

Press again to co

The fault memory is dunlocked.

Continue with Heater

98

res

rm the diagnosisn was unsuccessful

atic detection was not successfully

arness not connected to heater harness

not seated in diagnostic harness

gnostic cable

ater.

Heater Start-Up Procedu

Quit Start-UpSwitch off heater

Press the heater is switched off.

Perform the diagnosis again

Press the display is activated.

Unable to perfoAutomatic detectio

Display if the automcompleted.

Possible causes:

• Diagnostic h

• Adapter plug

• Defective dia

• Defective he

99

BLANK PAGE

100

rt-up Procedures

harge

tarting the APU engine, oil and coolant levels ent damage to the engine and the A/C system rge of refrigerant added to prevent damage to the leeding the Coolant System” on page 102 and s” on page 104 before adding a partial

nt bottle to the gauge manifold and place it on a

bottle valve for liquid and purge the charging line.

re side valve of the gauge manifold closed. Open e valve.

reaching 1 lb. 8 oz. of R-134a.

bottle valve and the high side valve of the gauge

pecial Tools Required

A/C System Charging and APU Engine Sta

A/C System Charging and APU Engine Start-up Procedures

This is a multi-step procedure consisting of:

a. adding a partial refrigerant charge to the system

b. verifying APU engine has the proper amount of oil

c. bleeding air from the APU cooling system

d. bleeding air from the APU fuel lines

e. running the APU with the A/C operating and adjusting the engine rpm’s

f. system fluids leak check

g. verifying alternator output voltage

h. adding a full refrigerant charge to the system

Adding Refrigerant C

IMPORTANT: Before smust be checked to prevmust have a partial chaA/C compressor. See “B“Bleeding the Fuel Linerefrigerant charge.

1. Connect the refrigerascale.

2. Open the refrigerant

3. Keep the low pressuthe high pressure sid

4. Add refrigerant until

5. Close the refrigerantmanifold.

S

R134a Refrigerant

Scale

101

art-up Procedures
A/C System Charging and APU Engine St

102

rt-up Procedures

t from the TriPac back into the tractor’s radiator.

m. See “Bleeding the Fuel Lines” on page 104.

U engine has proper amount of oil and the A/C erant charge before starting the engine.

-In Test” on page 112 before performing the

.

e system will be forced to the tractor radiator ould now be bled of all air.

he Closed Loop Cooling Option

with air trapped in the block, the engine may be temperature switch may not protect an engine block, because the high water temperature ct an engine from overheating due to failures

the loss of coolant.

ooling system is refilled, air is trapped in the the thermostat. Use the following procedure to nd the cooling system:

under the TriPac bleed line to catch the coolant

the TriPac engine to allow air to bleed out.

September 2006 have the bleed petcock on top . On theses units, remove the water pump air until there is a stead stream of coolant. ump bleeder bolt.

start the engine without bleeding the air out of

A/C System Charging and APU Engine Sta

APU Engine Start-up Procedures

CAUTION: DO NOT operate the APU engine before a partial refrigerant charge has been added or damage to the A/C compressor will result.

IMPORTANT: BEFORE operating the APU engine check the oil level. Add proper amount and type of oil if needed.

CAUTION: Units equipped with the Closed Loop Cooling Option only - Check sight glass on overflow tank to confirm coolant level before starting the APU’s engine.

Bleeding the Coolant SystemAPU’s Equipped with Traditional Tractor Coolant Integration

1. Verify APU OUTLET hand valve is CLOSED (tractor inlet, next to water pump). If this valve is left open, coolant will be sitting on top of the TriPac thermostat and not allow the TriPac engine to bleed air.

2. Open the APU INLET hand valve.

3. Place a clean container under the bleed line to catch coolant that is drained.

4. Open the bleed petcock on the APU engine to allow air to bleed out.

5. When a steady stream of coolant flows from the bleed line, close the petcock.

6. Open the APU OUTLET hand valve.

7. Replace drained coolan

8. Bleed TriPac fuel syste

CAUTION: Verify the APsystem has a partial refrig

NOTE: See “Service RunRun-in Procedures.

9. Start the TriPac engine

10. The remaining air in thand the TriPac APU sh

APU’s equipped with t

NOTE: If an engine runs damaged. The high waterthat has air trapped in theswitch is designed to protein the cooling system and

Often when a TriPac unit cengine block and/or underbleed air out of the block a

1. Place a clean containerthat is drained.

2. Open bleed petcock on

NOTE: Units built prior toof the thermostat housingbleeder bolt and bleed theThen reinstall the water p

TriPac APU Oil Specifications

Oil Capacity 4.5 qts.(including filter) 6.5 qts. Max.

Oil Type 10W-30 for temperatures at or above -13 F (-25 C)

5W-30 for temperatures at or below -13 F (-25 C) CAUTION: Do not the engine block.

103

art-up Procedures

ump Bleeder Bolt and Bleed Petcock Locations

. Water Pump Bleeder Bolt

. Bleed Petcock

1

2

A/C System Charging and APU Engine St3. Slowly pour coolant into the expansion tank until a steady stream of

coolant flows from the bleed line, then close the bleed petcock.

4. Slowly pour coolant to the expansion tank until the coolant level is at the top of the window in the expansion tank.

5. Install the expansion tank cap.

6. Bleed the TriPac fuel system. See “Bleeding the Fuel Lines” on page 104.

CAUTION: Verify the APU engine has proper amount of oil and the A/C system has a partial refrigerant charge before starting the engine

7. Start the TriPac engine and use a non-contact thermometer pointed at the water pump bleeder bolt to monitor the coolant temperature. The water pump bleeder bolt located next to the bleed petcock on the water pump (see Figure 1).

8. When the temperature reaches 150 F (66 C) for units with a 160 F(71 C) thermostats, or 170 F (76 C) for units with 180 F (82 C) thermostats, shut off the engine for 2 minutes to allow the thermostat to heat soak and open completely to purge air out of block, head, and water pump.

9. After 2 minutes, re-start the engine.

10. Remove the expansion tank cap and slowly pour coolant to the expansion tank until the coolant level is at the top of the window in the expansion tank, then reinstall the expansion tank cap.

Repeat steps 8 through 10 until the coolant level stabilizes. The TriPac APU cooling system should now be bled of all air.

Figure 1: Water P

1

2

104

tart-up Procedures

Fuel Return Line Fitting

Engine Speed Adjustment Screw

A/C System Charging and APU Engine S

Bleeding the Fuel Lines1. Locate the On/OFF switch inside the APU and turn the switch “ON”.

2. Crack open the fuel return line banjo fitting on the APU engine.

3. At the HMI:

• press MAIN POWER Key “ON”

• press APU SYSTEM Key “ON”

• press MODE Key to “AC”

• press FAN Key to set fan speed

• press UP or DOWN Keys to set the thermostat to 50 F (10 C)

• multiple start attempts will be required to start the engine.

NOTE: The fuel pump only runs when the engine is turning over. If the engine cranks for 30 seconds and fails to start, a start fault shutdown will be generated. This alarm code will have to be cleared before attempting another start sequence. 4. Close the fuel return line banjo fitting when a steady flow of fuel is

observed.

5. Allow engine to start.

Verifying Engine Operation1. Once the APU engine is running:

IMPORTANT: verify with a strobe light tachometer the engine rpm is 2350 RPM loaded (A/C clutch engaged). Adjust as required.

• check cooling system for leaks• check for fuel leaks• check for oil leaks• check for exhaust leaks• verify with a digital meter that the charging voltage at the battery

cables is at least 13.6 Vdc.

105

terconnect cable to the Interface Board and a laptop icrosoft Windows and Internet Explorer 8 or

uter” window on the computer.

lick on the “TK Monitor” drive. This will open up about 8 files.

SB Mini-B Connector (J39)

Unit Setup Procedures

Unit Setup ProcedureBefore performing the Run In Procedure and then release unit to customer, the TriPac EVOLUTION control system must be setup. You will program the system configuration and programmable features based on unit options and customer requirements. This procedure will use the TK Monitor communication software that is on the TriPac EVOLUTION Interface Board.

NOTE: For additional information about TK Monitor refer to TK 55739, Section 6, A51A, Communication Using TK Monitor.

NOTE: An Internet connection is not required to operate TK Monitor.

Required Tools• PC computer with Internet Explorer 8 or higher.

• Interconnect cable USB to Mini-B (TK 204-2000)

Enter TK Monitor1. Turn the unit on by pressing the Mode button on the HMI (the knob on

the left) for 2 seconds.

2. With control box cover removed. Check the green “heartbeat” LED on the Interface Board. It will flash rapidly when first turned on. After several seconds the flashing rate will slow to the normal rate of one blink per second.

3. Locate the USB Mini-B connector (J39) near the lower right of the Interface Board.

4. Connect the USB incomputer running Mhigher.

5. Open a “My Comp

6. Locate and double ca window showing

U

106

s

Unit Setup Procedure

.

7. Double click “START.BAT” to launch TK Monitor.

Window with 8 drives shown

107

he different screens available in TK Monitor. A

options and input unit identification information –


8. TK Monitor opens as an Internet Explorer window to the Dashboard Screen. On the left is a menu of tdifferent screen may be select by mouse-clicking any one of them.

.

9. Select the Unit Setup Screen. This screen allows the technician to configure the unit based on installed an important set up procedure after installation of the unit.

Dashboard Screen

108

s

TION INSTALLATION **


** IMPORTANT STEPS FOR EACH TRIPAC EVOLU

Unit Setup

10. Select Alternator Capacity. Choose the alternator model installed:

a. 65 Amps (Default)

b. 120 Amps

Unit Setup Screen

109

is mounted on the pre-cooler coil.

stem. The Arctic Option is installed. Sensor WT2 is

d Loop Cooling Tank is installed. Sensor WT2 is

t identification plate.

ination of six letters and numbers. It will help


11. Select Engine Cooling Option:

a. Standard: The APU engine cooling system is connected to the truck cooling system. Sensor WT2

b. Standard + Arctic (Default): The APU engine cooling system is connected to the truck cooling symounted on the adapter tube in the coolant return line.

c. Closed Loop: The APU engine cooling system is not connected to the truck cooling system. Closedisconnected or not installed.

12. Enter Unit Serial Number: Record the 10-digit TriPac EVOLUTION unit serial number from the uni

13. Enter Unit ID: Enter a unique unit ID number. The truck number is commonly used. Can be any combidentify data logger downloads.

14. Select Update Unit Setup:

a. Setup information will be saved.

b. Controller will restart so selections will take effect.

c. TK Monitor will lose connection and must be restarted.

110

s

Manual TK 55739, Section 3, Software for more e.


Programmable Feature SetupNOTE: The Battery Voltage Restart Value and Real Time Clock should always be set.

The TriPac EVOLUTION system allows customizing of many operating features. Refer to Diagnostic information about programmable features. Changes directed by the customer should be made at this tim

15. Restart TK Monitor. Select the Programmable Setup screen.

Programmable Setup Screen

111

lt 12.2 volts) - should not be higher than 12.4 volts.


16. Set Battery Voltage Restart Value:

a. Determine truck low voltage alarm setting.

b. Set TriPac Battery Voltage Restart Value to at least 0.2 volts higher than truck alarm setting. (Defau

c. TriPac EVOLUTION Unit Setup Procedures

17. Make any customer directed changes to other programmable settings.

18. Set Real Time Clock:

a. Click on the Set System Clock check box.

b. The Real Time Clock will be set to the time on the connected computer.

19. Select Update Setup:

a. Setup information will be saved.

b. Controller will restart so selections will take effect.

c. TK Monitor will lose connection and must be restarted.

112

cedures

e under load. The Run-In Test in the Service (using a high temperature setpoint) to run for

A, Communication Using TK Monitor.

w tank. This is to catch any coolant that may

TriPac EVOLUTION Unit Run-In Pro

Service Run-In TestBefore delivery of a TriPac EVOLUTION unit to the customer it must complete a 10 hour run-in with the enginTest screen will cause both the air conditioning system (using a low temperature setpoint) and the heating system10 hours.

NOTE: For additional information about TK Monitor refer to Diagnostic Manual TK 55739, Section 6, A51

1. Verify there is sufficient fuel in the fuel tank to operate the system for 10 hours.

2. Closed Loop Cooling Option Only - Place a clean container under the overflow hose of the APU’s overflobe expelled during the initial 10 hour engine run-in.

3. Start TK Monitor. Select Service Test from the menu.

4. On the Service Test Screen select Run In Test.

Service Test Screen

113

rocedures

op automatically at the end of 10 hours.

Section 5, Diagnostics.

TriPac EVOLUTION Unit Run-In P

5. Select the Run Test button.

6. The APU engine will start and heater will ignite.

NOTE: Do not start truck after Service Test is initiated or the run in test will terminate.

7. Disconnect computer from the interface board – it is not required to complete the test. This test will st

8. A shutdown alarm will display on the HMI.

9. Reconnect computer and start TK Monitor.

10. Go to the Alarm screen.

11. Clear the code 54, Test Mode Timeout.

12. If any other alarms are listed diagnose and repair as required. Refer to Diagnostic Manual TK 55739,

13. Check engine oil level. Add oil as required.

114

System Check List

APU Mounting Bolts Positioned, Tightened and Torqued to Specs.

Coolant Hoses Routed and Secured Properly

Condenser Mounting Bolts Secured and Sealed with Silicone

A/C Receiver Drier Mounting Bolts Secured

A/C Evaporator Mounting Bolts Secured

Evaporator Drain Tube Water Valves (Kazoos) Installed

A/C Refrigeration Tubing Routed and Secured

All Wiring Harnesses Routed, Connected and Secured

A/C System Charged, Free of Leaks and Operates Correctly

Heater Intake and Exhaust Hoses Routed Safely and Secured

Heater System Operates Correctly

All Fuel Lines are Routed Safely and Secured

All Fuel Line Connections are Tight and Leak Free

All Guards, Covers and Grilles Installed Securely

3” access hole in the sleeper floor is completely caulked from both inside and underneath

Verified any unused holes in the sleeper floor are completely sealed closed with caulking

All System Run-In Procedures Performed

Coolant Levels for Truck and APU are Topped Off

Unit Operated For 10 Hours

Thoroughly Clean and Vacuum Interior of Sleeper

Release to Customer

Installation Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2013 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

TriPac™ EVOLUTION Auxiliary Heating and Cooling

Temperature Management SystemTK 55676-19-IM (Rev. 5, 10/15)

tripac™ evolution · inside the tractor provided you adhere to the following conditions: †...

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